Electrical coil winding device

ABSTRACT

A conductive strip is wound onto a rotated coil while a roller presses the periphery of the coil to prevent a buildup of material along an edge of the coil. The roller is rotatably carried adjacent to the free end of a pivoted arm and constantly biased into engagement with the coil. One end portion of the roller has a reduced diameter portion to accommodate an electrical lead for application to the coil.

United States Patent Benton A. Whiteman Richmond, Va.

May 9, 1968 Mar. 30, 1971 Reynolds Metals Company Richmond, Va,

Inventor Appl. No. Filed Patented Assignee ELECTRICAL COIL WINDING DEVICE I 7 Claims, 11 Drawing Figs.

Int. Cl B65h 39/16 Field of Search 242/56] [56] References Cited UNITED STATES PATENTS 1,574,059 2/ 1 926 Reynolds 242/708 2,276,980 3/1942 Jacobi 242/56.1X 3,008,222 11/1961 Steinmayer 29/605 3,058,201 10/ I 962 Richardson, I r. 29/605 3,066,388 12/1962 Cooper 29/605 3,163,374 12/1964 Horn et a1 242/561 Primary Examiner-Billy S. Taylor AttorneyGlenn, Palmer, Lyne, Gibbs and Thompson ABSTRACT: A conductive strip is wound onto a rotated coil while a roller presses the periphery of the coil to prevent a buildup of material along an edge of the coil. The roller is rotatably carried adjacent to the free end of a pivoted arm and constantly biased into engagement with the coil. One end portion of the roller has a reduced diameter portion to accommodate an electrical lead for application to the coil.

Patented March 30, 1971 4 Sheets-Sheet 1 mvemon BENTON A.WHITEMAN HIS ATTORNEYS Patented March 30,1971 3,512,603

4 Sheets-Sheet 3 INVENTOR BENTON A.WH|TEMAN BYM,@MW%

HIS ATTORNEYS ELECTRICAL COIL WINDING DEVICE CROSS REFERENCE TO RELATED APPLICATION This application is related to copending patent application, Ser. No. 497,069, filed Oct. 18, 1965, now Pat. No. 3,412,450.

BACKGROUND OF THE INVENTION Elongated strips of electrically conductive material used in forming electrical coil constructions are conventionally formed by slitting to define their opposite side edges. The slitting operation generally tends to create projections such as burrs, or the like, along the side edges of each strip, and also tends to curl the side edges of the strip. Upon winding a coil construction using presently known devices and methods and using an elongated strip formed by conventional slitting, the projections andcurled edges create problems such as preventing a completed coil construction from being easily installed in an associated housing. 1

SUMMARY This invention provides an improved device for and method of making a coil construction wherein the outside layer or turn of a coil construction is continuously flattened against the previously wound layers during the winding thereof to thereby provide a compact coil construction having the desired peripheral configuration and having minimum edge buildup.

Other details, uses, and advantages of this invention will become apparent as the following description of the exemplary embodiments thereof presented in the accompanying drawings proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings illustrate exemplary embodiments of this invention, in which FIG. I is a perspective view of an exemplary strip conductor coil construction made using the improved device of this invention;

FIG. 2 is a perspective view illustrating one exemplary embodiment of a coil winding apparatus which has the improved device of this invention provided as an integral part thereof;

FIG. 3 is a fragmentary perspective view illustrating electrical leads attached to an elongated strip of electrically conductive material used in forming theexemplary coil construction of FIG. ll;

FIG. 4 is a sectional view on the line 4-4 of FIG. 2;

FIG. 5 is a fragmentary view showing the manner of coupling a freely rotatable core carrying mandrel with drive means therefor;

FIG. 6 is a front view of one exemplary embodiment of the device of this invention;

FIG. 7 is a side elevation of the device of FIG. 6;

FIG. 8 is a plan view of the device as shown in FIG. 7;

FIG. 9 is a perspective view with parts broken away illustrating another exemplary embodiment of the device of this invention;

FIG. 10 is a front elevation with parts in section and parts broken away illustrating still another exemplary embodiment of the device of this invention; and

FIG. 11 is a view on the line 11-11 of FIG. 10.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS An exemplary strip conductor coil construction or coil made using the device and method of this invention is shown in FIG. I and indicated generally by the reference numeral 25. The exemplary coil 25 comprises a.tubular and substantially right circular cylindrical core element 26 which has a ribbon or strip 27 of electrically conductive material, such as aluminum foil, for example, wound thereon in a manner as will be hereinafter described. Strip 27 has an electrical lead 30 fixed to its inner end portion and an electrical lead 31 fixed to its outer end portion. The completed coil 25 is adapted to be installed in as associated electrical system with its leads 3t) and 31 suitably electrically connected in a known manner.

In many applications an associated housing, or the like, provided for coil construction 25 may be closely dimensionally controlled so as to provide minimum clearance between such housing and the completed coil construction. Therefore, it is necessary that the outer peripheral configuration of the coil construction be suitably controlled and wound as compactly as possible. The improved device of this invention designated generally by the numeral 29, makes possible the winding of the coil construction 25 in a tightly compacted manner with the desired outer configuration while substantially eliminating any buildup along opposite side edges of the completed coil construction which might be caused by projections in or curling of the side edge portions of the strip 27 used to make the coil construction 25.

In the exemplary coil 25 presented in FIG. I, the under side of the elongated strip of conductive material 27 preferably has a strip or coating of electrical insulating material prelaminated or applied respectively thereagainst before the strip 27 is wound on the core element 26. The insulating material electrically insulates adjacent coils or turns of the strip of conductive material 27 in a known manner.

The strip 27 may also be wound on core element 26 in unison with aseparate strip of insulating material so that the strip of insulating material is interleaved between adjacent coils of the strip of conductive material 27 to electrically insulate adjacent coils of strip 27 from each other. The improved device and method of this invention is also effective in providing a compact coil construction with minimum edge buildup when the strip 27 is interleaved with a separate insulating strip.

The exemplary coil winding apparatus used to form the strip conductor coil 25 of FIG. 1 in a substantially continuous manner is generally indicated by the reference numeral 32 in FIG. 2. The apparatus 32 includes a frame structure 33 rotatably carrying a supply roll 34 of electrically conductive strip material 27. As previously stated, the strip material 27 preferably has a strip or coating 35 of insulating material laminated to its lower surface, as illustrated in FIG. 3, to provide electrical insulation between adjoining coils.

The tubular core elements 36 may be made of cardboard, or the like, and are contained in a suitable hopper 36. The hopper 36 has a downwardly extending chute 37 extending from its lower end. Each core element 26 is adapted to be serially fed into a retainer 38 provided at the terminal lower end of the chute 37 and supported to enable it to be easily picked up by an associated mandrel in a manner to be subsequently described.

As illustrated in FIG. 2, the frame structure 33 carries a rotary table 39 which is adapted to be indexed in a rotary manner about a fixed vertical axis. The table 39 carries three actuating means or actuators shown as three fluid cylinders each designated by the reference numeral 40.

Each cylinder 40 has a telescoping rod 41 which carries support means enabling coil 25 to be formed thereon and such support means comprises a radially expandable and freely rotatable mandrel 42 carried at the terminal end of the telescoping rod 41. Each cylinder 40 is adapted to extend and yieldingly hold its mandrel 42 into operative engagement with drive means therefor in a known manner.

The table 39 is adapted to index the mandrels 42 through three stations 45, 46, and 47. When a mandrel 42 is indexed to station 45, the associated-cylinder 4t) extends associated rod 41 radially outwardly telescoping mandrel 42 within a core element 26 supported within retainer 32 at the lower end of hopper 36.

When the mandrel 42 at station 45 has a core 26 thereon, the associated piston rod 41 is retracted by cylinder 40 so that the core 26 is carried by mandrel 42 out of the retainer 35 whereby such retracted mandrel can be indexed from station 45 to winding station 46. Hopper 36 contains a plurality of cores 26 which are adapted to be serially dropped into retainer 38 through chute 37 as previously mentioned. As each core 26 is removed by an associated mandrel from the retainer 38 another core 26 drops in its place.

With the core carrying mandrel 42 now at station 46, the piston rod 41 thereof is extended to interconnect the mandrel 42 by a suitable driven clutch means 50 provided in its terminal outer end to suitable cooperating driving clutch means 51 provided on a rotatable drive shaft 53 comprising winding apparatus 32, see FIGS. 1 and 5. As the drive shaft 53 is rotated it rotates mandrel 42 at station 46 to cause the elongated strip 27 to be wound on the core 26 carried by the rotating mandrel 42 to define the coil 25.

Simultaneously with the winding of strip 27 on core 26 the forming or compacting device 29 and method of this invention assures the coil 25 is wound in a tight and compact manner without edge buildup and having the desired peripheral configuration in a manner to be described in detail subsequently.

After a completed strip conductor coil 25 has been formed on an associated mandrel 42 at station 46, the associated piston rod 41 is retracted to thereby disconnect the driven mandrel 42 from drive shaft 53 and specifically to thereby move the driven clutch means 50 away from driving clutch 51, whereby the retracted mandrel 42 is then indexed from station 46 to station 47. With the completed strip conductor coil 25 on mandrel 42 at station 47, the associated piston rod 41 is extended whereby the strip conductor coil 25 is held in a position at the station 47 so that a pair of stripping members each designated by the numeral 54, see FIG. 2, can strip the finished strip conductor coil 25 from mandrel 42.

The stripping members 54 are pivotally mounted on a support 55 by suitable pivot pins respectively carrying pinion gears disposed in meshing relation with each other. One of the stripping members 54 is interconnected to a piston rod 56 adapted to be extended and retracted by a fluid cylinder 57 carried by support 55. Thus, with a completed strip conductor coil 25 being held at station 47 by an extended mandrel 42, cylinder 57 is actuated to telescope its rod 56 outwardly and through the action of the above mentioned pinion gears stripping members 54 are brought into clamping engagement in a known manner on opposite sides of coil 25.

With the strip conductor coil 25 now firmly clamped between the stripping members 54 retraction of the piston rod 41 of the mandrel 42 at station 47 pulls such mandrel out of the core 26 of the completed strip conductor coil 25 so that the particular mandrel 42 can be subsequently indexed to the station 45 by indexing table 39. With the mandrel 42 at station 47 now retracted from core 26 of the completed strip conductor coil 25, the cylinder 57 can be deactuated to return the stripping members 54 to the open position illustrated in FIG. 2 whereby such members drop the completed strip conductor coil 25 onto a chute 58. The completed strip conductor coil 25 moves down the chute 58 to a table 60 for subsequent testing, packaging, and the like.

As illustrated particularly in FIG. 4, the elongated strip 27 is adapted to be fed from its supply roll 34 through a suitable slack reducing and tension applying roller device designated generally by the numeral 61. Thus, the strip 27 passes from its free wheeling supply roll 34 around a roller 62 carried by a frame portion 63 of device 61 which is pivotally mounted to the frame 33 of apparatus 32 by a pivot pin 64. The strip 27 continues from roller 62 around a pair of idler rolls 65 and 66 and between a combination guide means and bearing surface means designated by the numeral 67 and a table 70 to winding station 46 so that a given edge of the terminal end portion of the strip 27 being wound is held substantially in a fixed vertical plane during winding thereof at station 46.

A rod 72 is slidably carried by frame portion 63 and has a roller 73 rotatably supported at its lower end and resting on the supply roll 34. An arm 74 is provided and has one end pivotally mounted to the frame 33 by a pivot pin 75 and its opposite end adjustably carried by the rod 72. Ann 74 is interconnected to member 63 by an adjustable tension spring 76.

A suitable braking system is also provided for supply roll 34 and comprises a brake band 77 passed around a roller 80 which carries the supply roll 34. Band 77 has one end 81 fixed to the frame structure 33 while its other end 82 is fastened to the frame portion 63. it is to be understood that the purpose of the braking system for the supply roll 34 is to cooperate with the device 61 to provide a uniform tension of the strip 27 as it is fed through the apparatus 32; act as a shock absorbing means, particularly when the apparatus 32 is started; and to overcome the inertia of the rotating supply roll 34 when apparatus 32 is stopped.

As supply roll 34 is continuously used, less and less spring tension by the spring 76 is needed whereby the interaction of the linkages comprising device 61 together with spring 76 automatically provide the desired tension. For example, as the supply roll 34 decreases in diameter, the roller 73 carries the member 72 downwardly to thereby carry the right end of the arm 74 downwardly to lessen the tension of spring 76 the correct amount.

Apparatus 32 has means indicated generally by the numeral 83 for attaching leads 30 and 31 to elongated strip 27. Apparatus 32 also has a pair of taping heads designated respectively by the reference numerals 84 and 85 which are employed to start the strip 27 on core 26 as well as tape the final coil or layer of coil construction 25 in position to prevent unwinding thereof. The manner in which guide 67, table 70, and taping heads 84 and 85 are utilized in forming the coil construction or coil 25 will be more thoroughly understood by referring to the detailed description of similar components fully disclosed in the copending patent application Ser. No. 497,069 referenced above. However, a detailed understanding of the operation of components 67, 70, 84, and 85 is not necessary to thoroughly understand the operation of the exemplary device and method of the present invention which will now be described in detail.

One exemplary embodiment of a device used for preventing edge buildup during the winding of elongated strip 27 to define coil construction 25 is illustrated in FIGS. 6-8 of the drawings and as previously mentioned is designated generally by the reference numeral 29. Device 29 has a base 91 which is suitably fastened on a supporting bracket 92 which is fixed to the supporting structure 33 of the winding apparatus 32.

The device 29 has a roller 93 which is rotatably mounted on a support shown in the form of arm means or on arm which has a lower end portion 96 pivotally supported on the base portion 91 of the device 29 as will be described in detail subsequently. An actuator shown as a compression spring actuator and designated generally by the reference numeral 94 is also provided and such actuator is operatively connected to the arm 95 and is adapted to urge the arm toward an associated coil construction 25 and the roller 93 against the outer periphery of the coil construction 25 during winding thereof to assure such coil construction has the desired peripheral configuration.

The support or arm 95 may be of any suitable construction; however, in this exemplary embodiment of the invention such arm is comprised of a plurality of component parts suitably fastened together and as will be described in more detail subsequently.

The base 91 of the exemplary device 29 has a substantially U-shaped portion at its forward end defined by a pair of parallel spaced apart upwardly extending lets 101 which are adapted to receive the lower portion 96 of the arm 95 therebetween. Each upwardly extending parallel leg 101 has an opening 102 extending therethrough adjacent its upper end and openings 102 are arranged with their axes in aligned relation.

The lower end portion 96 of the arm 95 has a cooperating opening 103 extending therethrough and as seen in FIG. 6 the lower portion 96 is arranged with its opening 103 aligned between openings 102 of upwardly extending parallel legs 101 and a fastening pin 104 is extended therethrough to thereby pivotally mount arm 95 on the base 91. With the arm 95 thus pivotally mounted it will be seen that its outer end portion and hence the roller 93 is yieldingly urged against the coil construction 25 by the compression spring actuator and. in a manner as will be described in detail subsequently.

The outer or swinging end portion of the arm 95 comprises a substantially Y-shaped member 105 which has a pair of parallel legs each designated by the numeral 106 and defining a bifurcate end and each leg 106 has an opening 107 extending therethrough adjacent its terminal end and openings 107 are arranged with their axes in aligned relation.

The rotatable roller 93 has a central opening 109 extending therethrough and a shaft 1 is extended through opening 109 and through aligned openings 107 in legs 1% and suitably fastened in position to thereby freely rotatably support roller 93 at the tenninal upper end of Y-shaped member 105. Roller 93 is supported on Y-shaped member 105 with its central axis arranged substantially parallel to the axis of rotation of the coil construction 23 during the winding of such coil construction.

The central single leg portion of the vY-shaped member 103 is designated by the numeral 11 1 and has means for adjustably fastening member 105 at a plurality of positions to thereby control the effective length of the arm 93. The means for adjustably fastening Y-shaped member 193 in position comprises a bolt 114 which is threaded into a cooperating threaded opening provided in the central portion shown at 112 of arm 93 and an elongated slot 113 provided in the downwardly extending leg portion 111 of Y-shaped member 1113. Thus, it is seen that the effective length of the arm 95 and hence the position of roller 93 above pivot pin 104 is easily controlled by loosening bolt 114, sliding the Y-shaped member 1113 up and down as desired by mean of slot 113, and then tightening bolt 114 in position at the desired position of the Y-shaped member 105 and roller 93.

The exemplary device 29 has a substantially L-shaped support 1211 fastened on the base 91. The L-shaped support 120 has a horizontally arranged base portion 121 which is supported on base 91 and a bolt 122 is provided and extended through a suitable opening in base portion 121 and through a cooperating threaded opening provided in base 91 to fasten the L-shaped support 120 in position at the rear end portion of base 91. However, in some applications of this invention it may be desired to provide a support similar to support 120 which may be adjustably fastened along base 91.

The upwardly extending portion of the L-shaped support 129 has a pair of parallel spaced apart legs each designated by the numeral 123. A substantially cylindrical guide member or guide 124 is provided and supported for free pivoting movement between parallel legs 123. The guide 124 has an opening 123 extending therethrough substantially parallel to its cylindrical side surface and opening 123 is utilized in fastening the guide member 124 in position for pivoting movement.

Each leg 123 of the support 120 has an opening 131 extending therethrough adjacent its outer end and the openings 131 are arranged in axially aligned relation to enable receiving a cooperating combination pivoting and fastening shaft or bolt 1311 therethrough. The bolt 131) extends through the openings 131 and through the opening 123 in the guide 124 to thereby mount guide 124 on the upwardly or vertically extending portion of the L-shaped support 120 for free pivoting movement.

A compression spring 132 is also provided and with the bolt 1311 extending through the openings 123 and 131 the spring 132 is installed in position, see FIG. 8, and a nut 133 is threaded and tightened on the terminal outer end of the bolt 139 to thereby slightly compress the upwardly extending legs 123, which are made of a resilient material, toward each other in a yielding manner. This arrangement allows guide 124 to be freely pivoted under controlled conditions between the upwardly extending leg portions 123.

The guide member 124 has a substantially right circular cylindrical bore 134 extending therethrough. The bore 134 extends substantially perpendicular to the cylindrical outer surface of the guide 124 and hence substantially perpendicular to opening 123 and bolt 130.

The exemplary device 29 also has a rod 133 which has a fastened end portion shown at 133 which is fastened to the central portion 112 of the arm 93. Rod 133 has its end portion 136 fastened in a suitable swivel assembly 140 which is in turn fastened by a bolt 141 to the central portion 112. The swivel assembly 1411 enables free swiveling movement of the rod 133 for reasons as will be apparent hereinafter. The opposite end portion of the rod 133 is adapted to be extended through the cylindrical bearing surface 134 provided in the guide 124. Thus, as the arm 93 is pivoted about its pivot pin 104, the rear end portion of rod 133 slides baclr and forth along the cylindrical bearing surface 134 provided in the guide 124.

The previously mentioned compression spring actuator or compression spring 94 provided for normally yieldingly urging the roller 93 outwardly against the outer periphery of coil construction 23 is carried concentrically around the rod 133 and acts between the upwardly extending portion of L-shaped support 129 and the arm 93. As seen particularly in FIG. 7 of the drawings, the compression spring 94 has its forward end engaging swivel assembly 1411 while its rearward end engages a suitable washer 143 which is loosely carried around rod 134 and urged against the upwardly extending portion of the l.- shaped support 1211. Thus, the tendency is for the spring 94 to urge the entire arm 93 outwardly away from L-shaped support and hence outwardly away from the forward end portion of the base 91.

The compression spring 94 is selected so as to provide the desired amount of outward force against coil construction 23. Also, the structural design of the device 29 is such that the spring 94 may be easily installed and removed to thereby enable provision of the correct spring for each given type of coil construction.

Thus, it is seen that for each given type of coil construction 23 the length of the arm 93 is adjusted to the desired length. Further, the entire device 29 is fastened with its base 91 on supporting bracket 92 at the desired position with respect to the winding station 46 at which coil construction 23 is being wound.

As the elongated strip 27 of electrically conductive material is wound about its core 26 carried on the mandrel 42, the roller 93 is yieldingly urged by spring 94 against the outside layer of the elongated strip 27 as it is being wound in coil form. As the coil construction grows in diameter the arm 93 is pivoted clockwise about its pivot pin 194 as viewed in FlG. 7 of the drawings. This pivoting movement about pin 104 by arm 93 is easily accommodated by the swivel 140 provided at one end of the rod 133 and by the arrangement of the guide 124 carried on the L-shaped support 120. Also, as the arm 93 moves in a clockwise manner, the rear end portion of the rod 133 slides axially through the cylindrical bearing surface 134 provided in the guide 124.

Thus, it is seen that the guide 124 assures that the roller 93 has its central axis maintained at the same angular relation relative to the axis of rotation of the coil construction 23 and further assures that the rod 133 moves freely over the entire angular movement of the arm 93 as it is pivoted about its pivot 194.

Device 29 has a dampener 131) fastened to the rod 133 adjacent its freely slidable end thereof. The rod 133 has the terminal end portion of its freely slidable end provided with threads designated by the numeral 143. The dampener 131) is preferably defined by a yieldable resilient rubberlike material which may be suitably molded about a threaded central portion such as an insert, or the like, which is preferably made of a metallic material to enable easy fastening of the dampener in position. The dampener 131) is easily adjustably positioned axially along rod 133 to thereby define the total movement or are through which assembly 93 can travel. Having once established the axial position of the dampener 130 along the rod 133, any suitable means such as a setscrew, or the like, may be employed to fix the dampener 139 at the desired position.

Upon moving a completed coil construction 23 away from the winding station 46, in the manner previously described,

the coil construction 25 is moved away from roller 93 which causes the compression spring 94 to forcefully urge the arm 95 outwardly toward winding station 46 and particularly toward the position previously occupied by the completed coil construction 25. This forceful urging action is dampened by the dampener 150 as the rod 135 is extended outwardly by spring 94 and the dampener 150 strikes against guide 124 carried by the L-shaped support 120. Thus, the dampener 150 limits and cushions the outward movement of the arm 95 and its roller 93 toward the winding station and hence toward the coil construction 25 to be wound at station 46.

The roller 93 is made of a substantially firm material which assures that once it is urged against the coil construction 25 during the forming thereof any projection, burr, or curled side edge portion which may comprise the strip 27 is pressed and mashed flatly against the completed layers of the coil construction 25 to thereby efiectively eliminate any tendency for a buildup along the edges of a particular coil construction. in one example of this invention the roller 93 was made of wood which not only provided the firm mashing surface which is required but also which resisted the tendency of the adhesive tape used in taping the terminal end portions of elongated strip 27 in position from adhering to the roller means 93.

As previously briefly mentioned in connection with the general description of the winding apparatus 32 the elongated strip of electrically conductive material 27 has electrical leads 30 and 31 suitably attached thereto by the lead attaching device 83. The inner lead 30, for example, provides a radial projection which projects outwardly of the normal outside diameter of a given coil construction. To compensate for such projection caused by lead 30, roller 93 has a reduced diameter portion shown at 153. The reduced diameter portion 153 is adapted to accommodate the inner electrical lead 30 and is suitably dimensioned to assure that the outer peripheral surface of the completed coil construction 25 has the desired overall smooth configuration and does not project outwardly in an undesirable manner.

The exemplary device 29 is suitably fastened in position on the supporting bracket 92 which is fixed to supporting structure 33. Means is provided for adjustably fastening the device 29 on the flange 92 and with respect to the coil construction 25. in this example of the invention, an elongated slot 155 extends completely through base portion 91 substantially parallel to rod 135 and substantially perpendicular to the central axis of the roller 93. A volt 156 is provided for fixing the device 29 in position against flange 92 by threading bolt 156 through the cooperating threaded opening provided in bracket 92. As seen in FIG. 8, it is a simple matter to loosen the bolt 156 and slidably position the entire device 29 toward and away from the coil construction 25 utilizing slot 155 and once the desired position is reached the entire device 29 is fastened firmly in position by the bolt 156.

The device 29 has been illustrated and described in this example of the invention in connection with the winding of the elongated strip of electrically conductive material 27 which has an insulating layer 35 suitably applied or laminated to one of its surfaces. However, it will be appreciated that the exemplary device 29 described above'and similar devices to be described hereinafter may be used in a coil winding apparatus, or the like, wherein the elongated strip of electrically conductive material is wound simultaneously with a separate insulating strip and in a known manner.

Another exemplary embodiment of this invention is illustrated in FIG. 9 of the drawings. The device illustrated in FIG. 9 is very similar to the device 29; therefore, the device of FIG. 9 will be designated generally by the reference numeral 29A and parts of the device 29A which are very similar to corresponding parts of the device 29 will be designated by the same numeral as in the device 29 also followed by the letter designation A and not described again. Only those component parts of device 29A which are substantially different from corresponding parts of the device 29 will be designated by a new numeral also followed by the letter designation A and described in detail.

The device 29A has a base 91A which may be suitably fastened to the supporting bracket 92 which is fixed to the supporting structure 33 of the winding apparatus 32. The base 91A has an upwardly extending plate 160A fixed thereto adjacent one end and another plate 161A fixed thereto adjacent its opposite end. The device 29A also has a shaft 162A which has one end supported by the plate 160A for free pivoting movement and its opposite end portion is supported for free pivoting movement in a support block 163A which is supported on the plate 161A.

A support or ann A is provided and has its lower end portion 96A suitably fixed to the shaft 162A so that as the shaft 162A is pivoted, i.e., rotated through a limited arc, the arm 95A is also pivoted so that its outer or swinging end is pivoted toward and away from the coil construction 25. Although in the device 29 which was previously described the arm 95 is in the form of an arm assembly comprised of a plurality of component parts, it will be seen that the arm 95A of the device 29A is provided as a single member.

A roller 93A is rotatably mounted on the support or arm 95A adjacent its swinging end and in this example of the invention the roller 93A is mounted by a bolt 1 10A which serves as a shaft enabling substantially free rotation of the roller 93A. The roller 93A is supported by the bolt A in a substantially cantilevered manner and with a reduced diameter end portion 153A thereof arranged in position to accommodate the inner electrical lead 30 of the coil construction 25.

The device 29A has an actuator in the form of a torsion spring actuator which is designated generally by the reference numeral 165A and actuator 165A has one end 166A operatively connected to the arm 95A by being inserted through a cooperating opening provided in the lower end portion 96A of the arm 95A and the opposite end of the torsion spring actuator 165A is operatively connected to a spring adjusting assembly 170A which is supported by the support block 163A. The torsion spring actuator 165A yieldingly urges the upper swinging end of the arm 95A toward the coil construction 25 and the roller 93A yieldingly against the outer periphery of the coil construction 25 during the winding thereof.

The adjusting assembly 170A enables the amount of force exerted by the torsion spring actuator 165A to be adjusted and so as to provide accurate control of the force which is exerted by the roller 93A against the outer periphery of the coil 25 as it is being wound.

The compacting device 29A also has a dampener in the form of a dampening block 172A which is suitably fastened to the plate A. The dampening block 172A limits the movement of the arm 95A toward the coil construction 25. Once a coil construction 25 is completed it is moved abruptly away from the winding station 46; however, the torsion spring actuator A continues to urge the arm 95A and its roller 93A toward the winding station causing the arm 95A to be moved rapidly toward the winding station and against the dampener 172A. The dampener 172A cushions the arm 95A as it strikes thereagainst. The dampener 172A may be formed of any suitable resilient material and in some applications of this invention has been made of rubber.

The compacting device 29A also as a latch pin 173A which is supported by the plate 160A as illustrated at 174A. The latch pin 173A may be utilized for insertion in a cooperating opening in the arm 95A to hold such arm and the roller 93A in a position away from the winding station 46 to enable easier maintenance of component parts of the apparatus 32 which are located adjacent the winding station.

Another exemplary embodiment of this invention is illustrated in FIGS. 10 and 11 of the drawings. The device illustrated in FIGS. 10 and 11 is similar to the device 29 previously described; therefor, the device of FIGS. 10 and 11 will be designated generally by the reference numeral 298 and parts of the device 298 which are very similar to corresponding parts of the device 29 will be designated by the same reference numeral as in the device 29 also followed by the letter designation B and not described again. Only those component parts of the device 298 which are substantially different from corresponding parts of the device 29 will be designated by a new reference numeral also followed by the letter designation B and described in detail. I

The device 29B has a base portion 91B which may be suitably fastened to the supporting bracket 92 which is fixed to the supporting structure 33. The device 29B also has a pair of identical upright members each designated by the same reference numeral 175B and each being suitably fastened to the forward portion of the base 913 in spaced apart relation.

The device 29B has a support or arm 95B which has a lower end portion 968 pivotally supported about a pivot pin 1768 which extends through an opening 1818 through the lower end portion 963 of arm 95!! and through a cooperating pair of aligned openings 1828 provided in the spaced apart members 1758. The pin 176B is suitably fastened in position to one or both of the members 1758. The roller 93B is rotatably mounted on the support or arm 95B adjacent its swinging end and roller 938 also has a reduced diameter portion 1538 which is substantially identical to the reduced diameter portions H53 and 153A of the devices 29 and 29A previously described. The roller 93B is rotatably mounted in a cantilevered manner on the arm 958 by a bolt 1108 and the roller 93B has a friction surface 1858 which may be provided as an integral part of the roller 938. The friction surface 1858 is a right circular cylindrical surface and in this example is shown as having a diameter which is smaller than the diameter of the main portion of the roller 933.

The device 29B also has an actuator which in this example of the invention is shown as a pneumatic or air operated actuator which is designated generally by the reference numeral R873. The actuator 1878 is operatively connected to the sup port or arm 95B and normally holds the arm 958 in a retracted position, i.e., essentially as shown by dotted lines in FIG. of the drawings. The actuator 1878 is adapted to yieldingly urge the arm 95B toward the coil construction 25 and hence the roller 93B yieldingly against the outer periphery of the coil construction 25 during the winding thereof to assure that the coil construction 25 has the desired peripheral configuration.

The pneumatic actuator 187B comprises an air cylinder 19018 which has a cylindrical bore 191B extending axially therethrough and the bore 191B supports a piston 1928 for sliding movement therealong. The piston 1928 has a rod 193B suitably fastened thereto and a compression spring 1943 is provided and operates between a surface 1953 provided in the air cylinder 1903 and the piston 1928 to normally hold the rod 11933 in a retracted position within the cylinder 19013.

The terminal outer end of the rod 193B has a unit 1958 suitably fastened thereto which has an opening 196B extend ing therethrough. The unit 1958 is operatively connected to the arm 953 by extending a fastening pin 19713 through the opening 196B and suitably fastening the inner end of the pin 19718 to the arm 9513. The diameter of the opening 1963 is such that as the rod 193B moves arm 95B in a pivoting manner the unit 195B is free to rotate about the pin 1978.

The main body of the cylinder portion 1908 of actuator M78 is also fastened in position to allow limited pivoting movement thereof. In this example the device 293 has a bracket 198B fixed to the base 91B. A clamp 199B is fastened to the cylinder 1908 and the clamp 1993 has an integral pin 2008 which is adapted to be received in a cooperating opening 2018 in the bracket 198B whereby the cylinder 1908 is free to pivot relative to the bracket 198B. Thus, it is seen that the actuator 1878 of the device 298 is operatively connected to the support or arm 95B and the compression spring 1948 normally holds the support 95B and roller 938 in a retracted position away from the coil construction 25.

During the winding of a particular coil construction 25, air is applied to the rear face 2048 of the piston 1928 through a passage 205B provided at the rear of the air cylinder 190B ill The air cylinder 1903 is supplied with air under pressure through a flexibie conduit 2MB which is fastened in flow communication with the'passage 205B.

An adjustable pressure regulator 207B is also provided and suitably installed in the line 206B in a known manner. The adjustable pressure regulator enables the precise control of the pressure downstream of such regulator and hence enables a precise control of the air pressure acting against the face 2MB of the piston 1192B whereby the total force which is exerted by the piston against the spring 119418 to override such spring and as the force which is exerted by roller 93B against a coil construction 25 may be precisely controlled throughout the entire winding operation. It will also be appreciated that a substan-' tially constant compacting force can be applied against each outer turn of the coil 25 throughout the entire winding process, i.e., from the beginning of the coil winding operation until a given coil 25 (which may have a substantial number of turns) is completed. It will also be appreciated that the force exerted by the pneumatic actuator 1873 against a coil construction may be adjusted to suit the particular requirements of a given coil and the nature of the material utilized to form the coil, as desired.

As previously mentioned the roller 938 has an integral friction surface 1858 provided adjacent the inner end portion thereof and the friction surface 185B may be made of a metallic material, if desired. The device 298 also has a friction brake designated generally by the reference numeral 2085 which is carried by the support or arm B and is adapted to engage the friction surface 1858 to enable a more effective compacting of each coil construction 25.

The brake device 2088 is supported on the arm 958 by a pair of lugs 2098 and 2103. The upper lug 2108 has a cylindrical bore 2MB extending therethrough which is adapted to receive and allow free axial sliding movement of a shaft 2128 provided at the lower end portion of a brake shoe 213B comprising the brake device 2088. The brake shoe 2133 has a semicylindrical friction surface 2143 which is adapted to engage the cylindrical friction surface 1358 and restrain the free rotation of the roller 938 as it is urged against a coil construction 25 during the winding thereof.

The lower lug 20913 of the brake device 2MB has a threaded opening 218B extending therethrough. A threaded member 22013 is also provided and is threaded through the threaded opening 2183. The member 2208 has a lower knob 2213 which enables easy threading of member 2203 through the threaded opening 2188 and toward and away from the lug 210B. A compression spring 2MB is also provided and extends between the lower end of the shaft 21123 and the upper end of threaded member 2208 and the compression spring 224B is effective in urging the shaft M23 and the brake shoe 213B against the cylindrical friction surface 1858.

The brake shoe 2138 is yieldingly urged against the friction surface 1858 by the spring 2248 to thereby restrain rotation of the roller 93B whereby a more effective compacting of the coil construction 25 is provided by the roller 93B rolling on and sliding against each outer turn of an associated coil construction 258. It will also be appreciated that the amount of frictional drag imposed by the brake shoe 2133 is adjusted by the amount that the upper end of member 2208 is threaded toward the upper lug 21013.

The device 298 also has a stop 2288 which is suitably fixed to the base 918 thereof and which is used to limit the movement of the arm 95B and hence the roller 93B toward the winding station M. The stop 2288 may be made of any suitable material which is effective in preventing damage to the arm 95B as it strikes thereagainst.

As previously mentioned, the device of this invention is par ticularly effective in not only preventing edge build up on an associated coil construction but is also effective in compacting the coil so that the diameter of a right circular cylindrical coil, for example, is reduced and provides a better fit within an associated housing. ln particular, it has been found that in coil constructions wherein the elongated strip of electrically conductive material comprises a strip of aluminum foil the amount of compacting provided results in a decrease in diameter generally of the order of three percent as compared to a coil construction wound without using the device and method of this invention. However, it is to be understood that the total amount of compacting that may be provided in each application will be determined by the characteristics of the strip material being wound and by the amount of force exerted by the particular actuator being used, whether it be a spring actuator or a pneumatic actuator.

In each exemplary device of this invention presented above the compacting roller is of substantially right circular cylindrical peripheral outline and has a reduced diameter end portion which is adapted to accommodate an inner lead of the coil construction 25 and such coil construction is also of right circular cylindrical configuration. However, it will be appreciated that the compacting roller in each instance may be of any suitable configuration so as to correspond to the configuration of the particular coil construction being wound.

Further, the central axis of rotation of each of the compacting rollers in the above devices is arranged so that it extends substantially parallel to the central axis of the coil construction 25; however, it may be desired in some applications of this invention to provide suitable means so that the central axis of a particular compacting roller may be arranged and guided to move through a fixed angle and over a predetermined path with respect to the axis of rotation of the coil construction 25 whereby such technique would be effective in continuously shaping the coil construction 25 during winding thereof. Such a technique could be used to form a coil construction having a slightly tapered configuration, for example.

While present exemplary embodiments of this invention, and methods of practicing the same, have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced within the scope of the following claims.

lclaim:

1. In combination: an apparatus for winding an elongated strip of electrically conductive material to form a coil construction and a device for compacting said coil construction during the winding of said elongated strip said device comprising, a support, a roller rotatably mounted on said support, said roller having a reduced diameter end portion which is adapted to accommodate an electrical lead for said coil construction which is fastened to an associated side edge portion of the inner end of said elongated strip, and an actuator operatively connected to said support and urging said support toward said coil construction and said roller yieldingly against the outer periphery of said coil construction during winding thereof to assure said coil construction has a desired peripheral configuration.

2. A combination as set forth in claim 1 in which said support is in the form of an arm which is pivotally supported adjacent one of its ends and said roller is rotatably mounted adjacent its opposite swinging end.

3. A combination as set forth in claim 1 in which said actuator comprises a spring actuator.

4. A combination as set forth in claim 1 in which said actuator comprises a pneumatic actuator which exerts a predetermined substantially constant force against said support causing said roller to be yieldingly urged against said coil construction with a substantially constant force during the entire winding thereof.

5. In combination; an apparatus for winding an elongated strip of electrically conductive material to form a coil construction and a device for compacting said coil construction during the winding of said elongated strip, said device comprising, a support, a roller rotatably mounted on said support, said roller having a reduced diameter end portion which is adapted to accommodate an electrical lead for said coil construction which is fastened to an associated side edge portion of the inner end of said elongated strip, and an actuator operatively connected to said sup on and normally holdin said support and roller in a re racted position, said ac uator yieldingly urging said support toward said coil construction and said roller yielding against the outer periphery of said coil construction during winding thereof to assure said coil construction has a desired peripheral configuration.

6. A combination as set forth in claim 5 in which said roller has an integral friction surface and further comprising a friction brake carried by said support and engaging said friction surface to restrict the free rotation of said roller and provide more effective compacting of said coil construction by said roller rolling on and sliding relative to each outer turn of an associated coil construction.

7. A combination as set forth in claim 5 in which, said support is in the form of an arm which is pivotally supported adjacent one of its ends and has said roller rotatably mounted thereon adjacent its swinging end, said brake device is carried by said arm adjacent its outer swinging end, and said actuator comprises an air cylinder. 

1. In combination: an apparatus for winding an elongated strip of electrically conductive material to form a coil construction and a device for compacting said coil construction during the winding of said elongated strip said device comprising, a support, a roller rotatably mounted on said support, said roller having a reduced diameter end portion which is adapted to accommodate an electrical lead for said coil construction which is fastened to an associated side edge portion of the inner end of said elongated strip, and an actuator operatively connected to said support and urging said support toward said coil construction and said roller yieldingly against the outer periphery of said coil construction during winding thereof to assure said coil construction has a desired peripheral configuration.
 2. A combination as set forth in claim 1 in which said support is in the form of an arm which is pivotally supported adjacent one of its ends and said roller is rotatably mounted adjacent its opposite swinging end.
 3. A combination as set forth in claim 1 in which said actuator comprises a spring actuator.
 4. A combination as set forth in claim 1 in which said actuator comprises a pneumatic actuator which exerts a predetermined substantially constant force against said support causing said roller to be yieldingly urged against said coil construction with a substantially constant force during the entire winding thereof.
 5. In combination; an apparatus for winding an elongated strip of electrically conductive material to form a coil construction and a device for compacting said coil construction during the winding of said elongated strip, said device comprising, a support, a roller rotatably mounted on said support, said roller having a reduced diameter end portion which is adapted to accommodate an electrical lead for said coil construction which is fastened to an associated side edge portion of the inner end of said elongated strip, and an actuator operatively connected to said support and normally holding said support and roller in a retracted position, said actuator yieldingly urging said support toward said coil construction and said roller yielding against the outer periphery of said coil construction during winding thereof to assure said coil construction has a desired peripheral configuration.
 6. A combination as set forth in claim 5 in which said roller has an integral friction surface and further comprising a friction brake carried by said support and engaging said friction surface to restrict the free rotation of said roller and provide more effective compacting of said coil constRuction by said roller rolling on and sliding relative to each outer turn of an associated coil construction.
 7. A combination as set forth in claim 5 in which, said support is in the form of an arm which is pivotally supported adjacent one of its ends and has said roller rotatably mounted thereon adjacent its swinging end, said brake device is carried by said arm adjacent its outer swinging end, and said actuator comprises an air cylinder. 